Plastic frame construction



Aug. 20, 1963 R. c. WAGNER PLASTIC FRAME CONSTRUCTION Filed May 9, 1961INVENTOR.

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QM C, uw! BY United States Patent O 1 3,100,917 PLASTIC FRAMECGNSTRUCTIN Robert C. Wagner, RR. 4, Bellevue, Ohio Filed May 9, 1961,Ser. No. 108,871 2 Ciaims. (Cl. 20u16) This invention relates to frames,such las door `and window frames and sashes, `and particularly to aframe which is fabricated from extrusions of set synthetic organicplastic.

rPhe principal object of the invention is to provide a fname of thischaracter which is precisely shaped and which is reinforced in a mannersuch that whipping and bowing of the frame out of its normal plane aregreatly reduced.

For the purposes of illustration, the invention is described as appliedto a vinyl frame for screen or glass pane doors, its application toother types of plastic and frames being readily apparent from theillustrative eX- K ample.`

i Heretofore, in the formation of vinyl door frames, attempts have beenmade to obtain suiicient rigidity to prevent the fname from warping,bulging, Ior bowing out of its normal plane and to eliminate theso-called whip, by increasing the wall thickness. The whip isparticularly objectionable because it prevents the doors from seatingproperly in the door jamb `and also results in tth breaking of the glasspanes.

When such doors are closed with obstructing foreign objects between thedoor frames tand jambs, the doors flex. If a door is held by the latchin flexed condition for a predetermined period, it warps permanently inthe flexed shape.

These iframes almost lalways are fabricated from rails cut from plasticextrusions which are hollow or tubular so as to provide maximum rigiditywith as chin walls as possible, thus reducing the amount of therelatively expensive plastic required.`

To increase the vertical rigidity and reduce bowing, metal reinforcingtubes or channels of aluminum or steel have been inserted inside the`hollow or tubular extruded rails, and gussets have been used toreinforce the frames at the corners. rihis type yof construction is veryexpensive due to complex fabricating steps required and inconsistentresults obtained. To eliminate this diiiicwlty, an attempt was made toWeld or fuse the reinforcing members and gussets together at thecorners, and while a fairly rigid door could be obtained by this method,some whip remained 'and introduced sales objections, and the weldingoperation was very expensive.

Another approach was to eliminate the use of the its rejection. Forexample, the 'addition of webs and ribs did not yield sufficientlyincreased strength to prevent bowing of the door, and they causeddeformities in the face of the extrusion at their junctures therewith.These deformities adversely saifelcted the appearance and marketdesirability. Again, consistent tolenances could not be obtained onsuccessive extrusion runs.

In accordance with the Ipresent invention, the frame of extruded plasticis so arranged that la simple hollow or tubular extruded section `ofaluminum or like material can be secured thereto easily and cooperatetherewith to reinforce the frame adequately and thereby reduce warp ingand whipping to an unobjectionable amount.

Various other Iobjects and advantages will become apparent from thefollowing description wherein reference is made of the drawings, inwhich:

FG. 1 illustrates a front elevation of a door frame embodying theprinciples of the present invention;

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FlG. 2 is an enlarged fragmentary View of the upper right-hand corner ofthe frame illustrated in FIG. l, partly in section, showing thearrangement of the 'frame rails and the connection of the reinforcingmembers; and

FIGS. 3 and 4 are enlarged cross sectional views taken on the lines 3 3and 4 4, respectively, in FIG. l. g

Referring to the drawings, lthe door frame comprises essentially a pairof spaced side rails or frame members 1 with cross end rails or iframemembers E connected to the ends thereof. lf desired, la suitable crossrail or frame member 3 may be provided intermediate the ends of the sideframe members 1. The side frame members 1 and the end frame members 2are lengths cut from identical extrusions of vinyl or suitable setplastic, such as high impact plastic. Each comprises a hollow tubularportion 5 having an outer decorative side Wall 6 and an inner side wall7, joined by an outer peripheral wall 8 and inner periphenal wall 9. Thewall 9 has a flange 10 extending inwardly of the fra-me parallel to thewalls 6 and 7 and offset from the planes thereof so as to act as a stopfor a `framed Screen or pane installed in the opening defined by thewall 8. The frame members are tubular and, when assembled, the outerwall S is exposed outwardly of ,the finished door edgewise of the door.rllthe assembled frame has mitered corners, the frame members beingbonded together at the corners 'by fusion of the plastic material at thejuuncture, either 'by heat or plasticizers. Thus the vinyl frame becomesa unitary structure.

The side walls 6 and 7 have integral flanges 11 which, together with thewall 8, define an outwardly open peripheral channel 1?.. The anges 11are formed with shoulders or fabutments 13 whichprotrude inwardly fromthe flanges and restrict the side of the channel 12. As a result, thechannel 12 can receive and lsnugly `accommodate a tubular reinforcingmember, such as indicated The tubular member 14 preferably is one havingan y i and the outboard face of the wall 15 is engaged along its margins`by the inner faces of the abutments 13 land thus -held securely in thechannel. The walls 17 of the member 14 preferably are juxtaposed in faceto face relation with the inner faces of the flanges 1li and 11. lfdesired, the member 1li may be cemented in place, thus increasing therigidity of the frame.

The member 1li is a tubular extrusion, preferably of aluminum or likemetal, and preferably is reinforced interiorly. On its inner wall 16, itis provided with integral channels 1S which are so con'gured as toreinforce the inner wall 16. The open sides `of the channels 18 arerestricted so that the channels provide longitudinal open sided passages19. These passages are adapted to receive screws, as indicated at 20, incoaxial relation therewith for securing the reinforcing members 14together to form a mitered corner. By the use of self-threading screws,the members 14 can 'be drawn tightly together at the corners of theframe. The passages 19 extend longit=udinally of the members 14 and arepreferably coeXtensive with the length thereof.

Whenithe members 14 are assembled together, as illustrated in FIG. 2,they completely embrace the frame, each side frame member 1 and topframe member Z being provided with a. reinforcing member 14 coextensivein length therewith. The screws 20 are introduced through thereinforcing members of the side frame members by boring suitablehorizontal holes therethrough in alignment with the passages 19 in thechannels 1S. The screws 20 are then passed therethrough and threadablyengage the walls of the channels 1S by cutting their own threadsPatented Aue'. 20, 1963 e.y l

therein. rThey draw .the members 14 of the side frame members 1 and ofthe top and bottom fra-me membersV Z xedly together in position, so thatthey tightly embrace the peripheral edge of the frame. Thus, no weldingisV required and, a rigid reinforced door ystructure is provided withoutincreasing the thickness of the walls of plastic extrusion and withoutinternal webbing and the like. If facilities for welding `are available,the members `f4 may be connected together by welding, which, since Withthis arrangement, the `door frame is reinforced' and is madesufficiently rigid Without an increase in the thickness of the'walls ofthe plastic material and With- Vout expensive webbing. Likewise, thecombination can be effected without welding internal reinforcing membersand without specialized equipment, by the insertion of ordinaryself-threading screws.

However, if welding of the reinforcing members is desired, such can beeffected more readily as the reinforcing members are exposed exteriorlyof the rframe. Thus a frame of extrusions of vinyl or synthetic organicplastic material is provided which. has mitered fused corners andreinforcing members which rare readi-ly fastened together after theframe is otherwise compiete.

` its outer edge a pair of integral flanges inspaced face to In thoseinstances where the corners `formed by the A complete in and lof itself,of extruded tubular side, top,

and bottom frame members of identical cross section throughout theirlengths and of set 'organic plastic mate rial having mitered jointsfusion bonded together in xed position relative to each other `at thecorners, respectively, of the frame, each of said main frame membershaving at face relation to each other and extending lengthwise of saidouter edge the full length thereof and deining with said outer edge arohannel which opens outwardly edgewise of the main frame, the channelsof said members defining a continuons channel extending completely aboutthe outer peripheral edge of the main frame and opening outwardlyedgewise of the main frame, la reinforcing frame complete in and ofitself of stiff metal side, top, and bottom reinforcing members,respectively, said reinforcing iframeV being dis-posed in said channeland juxtaposed against the edges of the main frame therebetween andfilling the space between 'the flanges and having rniteredv joints atthe corners, respectively, the corners of the reinforcing frame beingdisposed for access exteriorly of the main frame for connection of thereinforcing members together at the corners in iirm embracing relationto the main frame, connecting means at the corners .of the reinforcingframe, respectively, each of said connecting mea-ns including at leastone screw assembly, at its associated corner, for operation from theexterior of the reinforcing frame, each connecting means securing itsassociated reinforcing members together at the tass'ociated'miteredcorner of the reinforcing frame independently of the main frame andholding the mitered surfaces of the associated reinforcing members in rmstressed juxtaposition with each other under pressure applied by thescrew; v

2. The structure according to olaim 1 Whereineacrh screw extends throughone of the reinforcing members, edgewise thereof from the outer edge ofthe reinforcing frame with its 'head rat the outer edge, and is slidableaxially thereacross l`and has a threaded inner end portion extendingendwise of the other reinforcing member at the associated corner and inthreaded engagement therewith, so that upon rotation of the screw saidmitered edges of Vthe associated reinforcing member can be drawn therebyinto said stressed relation.

References Cited in the le of this patent UNITED STATES PATENTS

1. A FRAME STRUCTURE COMPRISING A UNITARY MAIN FRAME, COMPLETE IN AND OFITSELF, OF EXTRUDED TUBULAR SIDE, TOP, AND BOTTOM FRAME MEMBERS OFIDENTICAL CROSS SECTION THROUGHOUT THEIR LENGTHS AND OF SET ORGANICPLASTIC MATERIAL HAVING MITERED JOINTS FUSION BONDED TOGETHER IN FIXEDPOSITION RELATIVE TO EACH OTHER AT THE CORNERS, RESPECTIVELY, OF THEFRAME, EACH OF SAID MAIN FRAME MEMBERS HAVING AT ITS OUTER EDGE A PAIROF INTEGRAL FLANGES IN SPACED FACE TO FACE RELATION TO EACH OTHER ANDEXTENDING LENGTHWISE OF SAID OUTER EDGE THE FULL LENGTH THEREOF ANDDEFINING WITH SAID OUTER EDGE A CHANNEL WHICH OPENS OUTWARDLY EDGEWISEOF THE MAIN FRAME, THE CHANNELS OF SAID MEMBERS DEFINING A CONTINUOUSCHANNEL EXTENDING COMPLETELY ABOUT THE OUTER PERIPHERAL EDGE OF THE MAINFRAME AND OPENING OUTWARDLY EDGEWISE OF THE MAIN FRAME, A REINFORCINGFRAME COMPLETE IN AND OF ITSELF OF STIFF METAL SIDE, TOP, AND BOTTOMREINFORCING MEMBERS, RESPECTIVELY, SAID REINFORCING FRAME BEING DISPOSEDIN SAID CHANNEL AND JUXTAPOSED AGAINST THE EDGES OF THE MAIN FRAMETHEREBETWEEN AND FILLING THE SPACE BETWEEN THE FLANGES AND HAVINGMITERED JOINTS AT THE CORNERS, RESPECTIVELY, THE CORNERS OF THEREINFORCING FRAME BEING DISPOSED FOR ACCESS EXTERIORLY OF THE MAIN FRAMEFOR CONNECTION OF THE REINFORCING MEMBERS TOGETHER AT THE CORNERS INFIRM EMBRACING RELATION TO THE MAIN FRAME CONNECTING MEANS AT THECORNERS OF THE REINFORCING FRAME, RESPECTIVELY, EACH OF SAID CONNECTINGMEANS INCLUDING AT LEAST ONE SCREW ASSEMBLY, AT ITS ASSOCIATED CORNER,FOR OPERATION FROM THE EXTERIOR OF THE REINFORCING FRAME, EACHCONNECTING MEANS SECURING ITS ASSOCIATED REINFORCING MEMBERS TOGETHER ATTHE ASSOCIATED MITERED CORNER OF THE REINFORCING FRAME INDEPENDENTLY OFTHE MAIN FRAME AND HOLDING THE MITERED SURFACES OF THE ASSOCIATEDREINFORCING MEMBERS IN FIRM STRESSED JUXTAPOSITION WITH EACH OTHER UNDERPRESSURE APPLIED BY THE SCREW.